Metal working



C. E. KRAUS Jan. Q3, 1939.

METAL WORKING Filed Dec. 21, 1936 4 Sheets-Sheet 2 v Y I f%1 ,A l

` Jan. 3, 1939.

C. E. RAUS 142,517

METAL WORKING Char/es 6. )17a/us a7 fm1 @Y crroqvgys y attacked from another angle.

Patented Jan. 3, 1939 i UNITED STATES PATENTl OFFICE 2,142,517 Y METAL WORKING' vCharles Edward Kraus, Rockford, Ill., assignor to The Ingersoll Milling Machine Company, Roekford, Ill., a corporation ol' Illinois Application December 21, 1936, Serial No. 116,931

26v Claims. (Cl. 90-18) This invention relates to the removal of layers of metal from work pieces to form smooth and ticed, the active cutting edges are so shaped andv positioned that the chip thickness is measured in the general direction of the feed between the cutter and the work and therefore varies with the speed of the cutter and the rate of feed; whereas the width ofthe chip is measured in a direction normal to the feed and is determined by the thickness ofthe metal layerto be`v removed from the work. Since the maximum permissible chip thickness, when not limited by finishing requirements, is f determined largely by the character of the material of which the cutting edges are composed, a fixed limitation is imposed on the maximum rate at which metal may be removed by these processes as now practiced.

The problem of increasing feed rate obtainable in face milling operations and the like has been It has been proposed to eliminate the relationship above referred to between therate of feed and the chip thickness by so arranging the cutting' edges ofthe rotary cutter that the chip thickness is measured at right angles to that of the cutter feed and .therefore remains constant as the feed is rincreased. This general process forms the subject matter of Patent No.'2,081,639.

The general object of the present linvention is to improve upon the process last mentioned and provide a novel methodV and apparatus by which face milling and analogous operations may be i carried out'in practice at feed rates many times greater than the maximum now capable-of being obtained in practice even when the most improved cutting materials are employed. In addition, the inventionaims to produce smoother and more accurately formed surfaces-in a single op-` The invention also resides in the novel construction of the cutter and the blades thereof.

Other objects and advantages of the invention will becomel apparent from the following detailed description taken in connection with the accompanying drawings, in which Figure l is a perspective view partially in section showing the elements of a. typical milling machine in which the present invention may be practiced.

Fig. 2 is a lfragmentary cross sectional view through one of the cutter Vblades and its mounting.

Fig. 3 is a perspective view of the cutter.

Fig. 4 is an approximately actual size elevational view Aof one of the .cutter blades.

Fig. 5 is an edge elevational view of the blade shown in Fig 4.

Fig. 6 is an enlarged fragmentary elevational View of the edge portion of the blade shown in lFig. 4.

Fig. 7 is a view similar to F18. 6 of a blade having a differently dimensioned cutting edge.

Fig. 8f is a sectional view of a work piece being operated upon by a blade shown on the same scale as in Fig. 6, the section being taken longitudinally of the blade.

Fig. 9 shows on the same scale as Figs. 6 and 8 the shape and arrangement of the chips removed by the blade shown i'n Fig. 6.

Fig. 10 is a iView similar to Fig. 9 showing the shape and positions of the chips when a slower feed rate is employed.

Fig. 11'is a fragmentary view of a partially machined work piece.`

While the invention is susceptible of various modifications and alternative constructions, I have shown in the drawings and will herein describe in detail the preferred embodiment, but it is tobe understood that I do not intend to limit the -invention by such disclosure but aim to cover all modications and alternative constructions falling within the spirit and scope vof the invention as expressed,A in the appended claims.

Generally stated, the invention involves the use of a multiple blade rotary cutter having elongated cutting edges annularly arranged and generally parallel to the Vwork surface to le formed and each divided lengthwise into a series,l usually more than four, of edge portions' progressively stepped extremely small distances (see Figs. 4 and '1) apart for engagement successively with the work and each having steps of lengths many times their individualheight. The successive blades cooperate to form groups of cutting edges extending around the cutter axis spirally or helically according to the character of the metal removing operation to` be performed. A large number, that is one for each blade, of such spiral groups of edges are thus provided, these being arranged in overlapping relation as indicated by the dot-dash lines in Fig. 3.

The improved method includes rotating the cutter with the stepped edge portions arranged as above described, positioning the work piece to vbe machined-relative to the cutter withl the fedge portions or steps last to engage the work coinciding with the work surface to be formed, and finally relatively feeding the work and the cutter at a rate correlated with the length andheight `of the steps, the speed of the cutter, and the number of blades thereon.

This rate is such that in the combined rotary and feeding movements, the adjacent overlapping spiral groups of steps traverse overlapping curved zones of the work and cut from each zone successive layers of metal extending parallel 4to the finished work surface which is formed by the last step, each of such layers being of a width in the direction of the feed several times the thickness of the layer due to the height of the individual step. To facilitate the formation of a smooth finished surface, the steps on each blade vary in height so that the layers of metal removed by the last acting steps are thinner than those cut by the steps which rst engage the work.

By arranging the cutting edges in such a large number of spiral or helical groups spaced unlu formly around the cutter and each overlapping .rangement also facilitates production' of the blades at low cost and accurate grinding of the edges to form such ilne steps with the required accuracy.

The invention -is especially applicable to the' performance of face milling operations and accordingly is shown in the drawings embodied in a typical form of millingmachine that might be ltiiied in the description and claims in the order used for facing one side of a workpiece I2. While being operated upon, the work is secured by suitable clamps upon a work support 'in the form ofa table Il slidable alongways I l ona bed I5 so as to move the work across the face of a cutter I l. The latter is carried by a spindle Il rotatably supported with the proper 'rigidity in the machine frame (not shown) and driven through suitable gearing Il by power derived from an appropriate source such as an electric motor Il..

Relative feeding movement between the cutter and the work at-the required rate later to be nism including gearing to a screw Il meshing with a rack 22 on the table.

As shown in Figs. 2 and 3, the cutter I B comprises a generally cylindrical body 23 having relatively closely spaced slots 2| in one face extending radially or substantially so and inclined so as to provide the rake angle desired. The slots are spaced uniformly around the cutter face and receive unitary blades 25 each positioned a with one end extending beyond the end of the slot and a sideportion projecting fromthe face of the body. Herein each blade comprises a generally rectangular block of cutting material having an elongated continuous cutting edge 26 formed along the leading edge of an exposed .surface 21 which is sloped away from the cutting edge to afford proper clearance.

'The blades may be locked in the cutter body in various ways. In the present instance, each is clamped against the bottom and one side 'wall of the slot by an inwardly tapering wedge 28 received between the blade and the opposite wall of the slot and held in wedged position by a screw 29 threading into the body with its head overlying the wedge.

As contemplated by the present invention, the cutting edge 26 of each blade is divided longitudinally into a relatively large number, eight in the present instance, of edge portions or steps 3l individually identified by letters. Preferably, the steps are of equal length, substantially straight throughout their lengths and disposed parallel to each other. 'I'he adjacent ends of the adjacent steps are Joined by a plurality of short intervening transverse edge portions 3| preferably rounded or inclined as shown at a relatively small angle, for example 30 degrees, to the steps `lll so as to avoid the formation of sharp corners 'at the juncture of the edges 3|! and 3|. The step il* merges with a similar but somewhat longer transverse edge portion 32 on the outer end of the blade. As Vshown in Fig. 5, surfaces 33 are ground on each blade to provide proper clearance for the transverse edge portions ll. y

The blades are mounted on the cutter body so that the step 3l* will first engage the work as the cutter and work are advanced toward each other. Accordingly, for face milling, the blades extend radially when supported in the slots 24 with the steps "at the outer ends of the blades spaced equidistant from thegzytter axis. These and the succeeding steps of all of the blades are preferably disposed throughout their lengths in planes perpendicular to and spaced progressively along the cutter axis and away from the hat end face of the bodyherein shown.

For convenience, the blade steps will be idenof their engagement with the work during a metal-removing operation, and the perpendicuthe first step, the edge il as the second step,`

etc., the final step which removes the last layer of metalr being calledY the last step.

face, the vsteps Il* to IIIh or certain of them are formed of di'erent height, decreasing `from the outer to the inner or finishing steps so that the lhighexmsteps remove metal layers of decreasing .thickness, the final layer being extremely thin. I As above set forth, a fundamental characteristie of the present invention is that the chips removed by the individual edge -portions 30 are To improve the smoothness of the finished surof widths measured inthe direction of the cutter 7s feed many times greater than their thickness which ls determined by the height of the individual steps. Thus, for operating upon the rough surface of castings and the like, the steps might, for example, be proportioned as shown in the actual size view, Fig. 4, and in the enlarged dimensioned View, Fig. 6, the length of each step being of an inch.

To obtain optimum cutting efliciency and long cutter life, it is preferred to employ steps having a maximum height of approximately 0.020 of an inch or even less. shown, the first three steps are of this maximum dimension while the succeeding steps decrease progressively in height, the last or innermost step 30h being .003 of an inch so as to form a very smooth finished surface. A cutter 'with the blades thus dimensioned would be especially suited for operation upon the rough surfaces of castings, the combined height of the steps being such asl to effect removal of a metal layer having an average depth of approximately 3; of an inch. Of course, the proportion of maximum -depth steps or the total number of steps may. be varied as desired to correspond to thickness of the metal layer to be removed. Likewise the lengths of the individual blade steps, the number of blades, and other characteristics of the cutter may be changed to suit operating conditions, it being apparent that the particular cutter is merely typical of many that might be used.

'I'he steps on all of the blades, when constructed and positioned as above described, cooperate to form a series of overlapping rows or groups of cutting edges each arranged spirally of the cutter face whenthe cutter is used for face milling. Thus, the first or outermost edge 30 of each blade cooperates with the successive inwardly spaced edges 301 to 30h of succeeding seven blades to form one spiral row indicated by one of the dot-dash lines in Fig. 3. Since one such spiral group originates with the first step of each blade, the number of groups is equal to the number of blades in the cutter, there being thirty in the present instance. Each spiral row embraces as many bladesl circumferentiallyas there are steps on each blade and overlaps the adjacent spiral rows and projects at its ends beyond such rows by the distance between two adjacent blades. By providing such a large number of -groups equally spaced around the cutter with the adjacent groups overlapping as indicated by the dotdash lines inv Fig. 3, the number of cuts being taken and the amount of metal being removed by the edges engaging the work in any angular position of the cutter will be substantially constant. Accordingly, the reactionary torque exert-ed on the cutter is uniform and the cutter is therefore evenly loaded. f

By thus grouping the stepped edge portions and forming different steps of different spiral groups'integral with each other and on a common radial blade edge, the available face area of the cutter .body is utilized to maximum advantage, that is to say, a maximum aggregate length of effective cutting edges is obtained while at the same time providing ample space for chips. Thus,

.greater volume.

To cause operation of the spiral groups of cutthe radially extending slot between any two adjacent blades constitutes a common receptacle for the chips from one edge portion of several spiral groups, such receptacle increasing in width toward its outer end where the chips form in cutter approximately 30 inches in diameter.

In the exemplary cutter,

vmined bythe height of the steps.

relative to each other at a uniform rate such that during each revolution, the cutter is advanced a distance preferably approaching but less than the length of the individual steps 30 multiplied bythe number of blades. With a thirty blade cutter having blades dimensioned as shown, the work might, for example, be advancedl approximately eight inches per revolution or a total of over 90 inches per minute using a Of course, the maximum feed rate may be increased by lengthening the individual steps 30.

The maximum feed rate employed should a1- ways be such that the different steps will enter the work as shown in Fig. 8 and cut chips 35a to 35h (Fig. 9) having ends disposed, adjacent but nevertheless separated from each other. At such a rate of feed, the arcuate work zone over which each spiral group of edges passes as a result of the combined rotary and relative feed movements will always overlap the zone traversed by the adjacent preceding group of edges, and the width of the chips will approach the length of the steps 30 as illustrated in Fig. 9. If the cutter is fed at a slower rate, the widths of the chips will decrease correspondingly. At half the maximum feed rate, for example, chips of the shape and spacing shown Vin Fig.` 10 would be removed by the edges of each blade. Thus', while the rate of feed may vary considerably up to the maximum above referred to, such variations do not vary the thickness of the chips which thickness is determined solely by the height of the `individual steps of the cutting edges. The feed rate usually employed will be suilcient to produce chips having widths many times their thickness as deter- For example, at the maximum feed rate, the chips 35b and 35 formed by the highest steps 30h and 30 would be about fifteen times as wide as thick while in the thinner chips such as 35H, the ratio would be even greater. Ordinarily, the width of the thickest chip would be more than four times the thickness of this chip.

Proper correlation of the cutter speed and the feed rate may of course be effected in various ways well known in the art. Thus, the feed mechanism may be actuated through appropriate gearing from the same source of power as the cutter or, as shown herein, the two may be actuated by separate motors capable of operating at substantially constant full load speeds. The proper ratio of feed to cutter speed may be obtained by proportioning the power transmitting connections, suitable means such as pick off gears in the feed mechanism being provided to permit changes in the feed rate.

The machine above described is adapted to face mill surfaces of any width less than the mounted on the work support with the plane of` the innermost blade steps 30h coinciding with the plane of the surface 36 (Figs. 8 and 1l) to be formed- Preferably,l the number and height of the steps 30 are such that with the work thus positioned, the highest portion of the rough surface 31 will be disposed slightly above the plane of the step il!)al as shown in Fig. 8 so that ordinarily this step will not cut to a depth greater than the preferred maximum, that is, 0.020 of an inch. Thus, the transverse edge 32 will usually cut through the scale on the casting surface, but with sufficient variation in contour of the rough surface, the step may pass out of contact with the work, the first or even the second transverse edge 3l then cutting through the scale.

During the combined rotary and feeding movements between the work and cutter with the work thus positioned, the successive edges 30* to 30h of each spiral group move transversely across the work along arcuate paths indicated by the dot-dash lines in Fig. 11 and thus cut from a common zone of the work successive metal layers to 40h extending parallel to the finished surface 36 which is formed by the last step 10h. Due to correlation of the feed rate and the lengths of the steps 30, the'corresponding steps, for example 30, of succeeding spiral groups move across zones of the work which overlap in the drection of the feed and remove adjacent layers 40 from the rough face 31 to form surfaces 39e. The steps 30* to 3l' on any one bladeremov metal layers 40* to ll simultaneously from a'djacent portions of the work to form stepped surfaces n* to J9' spaced longitudinally of the work, the continuous finished surface 36 being formed by the ccmbined action of all of the steps 30h in removing the layers 40h as they traverse the overlapping paths.

Considering the number and lengths of the steps cn each blade and the number of blades engaging the work, it will be seen that the aggrearound one axial face of the cutter and each divided longitudinally into a plurality, more than four, of flat steps connected by a plurality of intervening edge portions extending transversely of the steps, the corresponding steps of the different edges being 'spaced equidistant from. and disposed throughout their lengths in common planes perpendicular to, the cutter axis, said planes being axially spaced apart by decreasing increments beginning with the outermost steps and the longitudinal length of the individual steps being more than four times the height thereof, means for supporting a work piece and said cutter for relative bodily movement transversely of the cutter axis with the plane of the innermost steps coinciding with the surface to be produced, and power driven mechanism correlated with the rotation of the cutter and operable to relatively feed the cutter and work during each revolution of the cutter a distance several times greater than the widest of said increments multiplied by the number of said edges but less than the longitudinal length of each step multiplied by the number of edges.

2. A machine for face milling comprising, in combination, work and tool supports mounted for relative feeding movement parallel to a work surface toibe formed, a power driven rotary cutter mounted on' said tool support with its axis gate length of the cutting edges acting at any Lpe'pendcular to said Surface' plurality 0f exon time is relatively large. Because of this coupled with the facts that the chips remain of constant thickness regardless of the rate of feed and the Ymaximum thickness of any chip 'is well within' cutting materials may be used without danger of deterioration at an objectionable rate inservice. By constructing the cutting edges as shown with the steps 30", 30h and 30 disposed in planes parallel tothe finished surface, these edges will be required to cut through the thin hard layer of scale on the work surface only in'rareinstances. This may occur when the contour of the rough surface changes so that the scale layer coincides with the edge 30* for example. Ordinarily, the scale will be cut by transverse edges 3| or 32. onwhichgnd substantial burden is imposed owirig,to the thinness of the scale layer.

The present inventionV may be utilized to equal advantage for the purpose of increasing the rate at which finishing cuts may be taken where an extremely'flne finish is desired. For this purpose, the cutting edges would be formed with a similar large number of .steps 30* to 30' of lesser height than in the construction above described. For example, the steps might be dimensioned as shown in Fig. 7, the first steps 30' and Il being a few thousandths of an inch high depending on the thickness of the nnishingcut to be taken and the ilnal steps Il and tlf being `.0005 and .0003 of an inch respectively. Actual tests show that itis practicable to cut metal layers of4 such small thickness in accordance with the present invention. l

I claim as my invention:-

l. A machinefor face milling comprising, in

l combination, a power driven rotary cutter having gated radially extending cutting edges on the cutter'fa'ce each divided longitudinally into five or more steps with the innermost steps disposed in the plane of the finished work surfacev and the other steps spaced toward the cutter variably increasing 'distances substantially less than the lengths of said steps,` and power driven mechanism operating to effect relative feeding mbvement between 'said supports at a rate such that the chip cut by each of said steps is wider in the direction of feed than thick due to the height of lthe different blades being disposed equidistant relatively feeding said cutter to advance the portions of each spiral set across a common zone of the work piece whereby to remove metal therefrom in successive layers of substantially greater width than thickness.

4. A machine for face milling comprising, in combination, a power driven rotarycutter having a plurality of blades extending generally radially of the cutter face, cutting edges on said.blades Veach divided longitudinally into a plurality, more than four, of spaced steps connected at adjacent ends by a plurality of transversely extending edge portions, the outermost steps of each blade and the succsive inwardly spaced steps o! the sucmove metal from adjacent overlapping zones of' the work piece in successive thin layers substantially parallel to said plane and of substantially greater Width in the direction of feed than in thickness.

5. A machine for face milling comprising, in combination, work and tool supports mounted for relative feeding movement parallel to a work l surface to be formed, a power driven rotary cutter body 'mounted on said tool support with its axis perpendicular to said surface, a plurality of elongated cutting edges on one end of said body extending vgenerally radially and each divided into a. plurality of steps of substantially greater individual radial length than axial height and .with the innermost steps disposed throughout their lengths in the plane of the' finished work surface, each` of said steps having an individual axial height of such small magnitude that the cutter and work piece may be relatively fed at a rate per cutting edge approaching the individual lengthof the steps Without increasing the thickness of the metal slices removed, and power driven mechanism operating to effect relative feeding movement between said supports at such a rapid rate that a continuous smooth work surface is formed and each of said steps cuts a slice of metal having a width measured longitudinally of said plane several times as great as the thickness of the layer normal to the plane.

6. A metal working machine comprising, in combination, a power driven rotary cutter having a plurality of elongated cutting edges disposed equidistant from the cutter body and each divided longitudinally into a succession of at least four spaced steps disposed parallel to the work surface to be formed and each having a length several times its height, the height of the individual steps decreasing in a direction from the first to the last step to engage the work, transverselyextending cutting edge portions connecting the adjacent ends of adjacent steps, means for supporting a work piece and said ctter for relative vbodily movement with said last'steps coinciding posed equidistant from the cutter body and each divided longitudinally into a succession, more than four, of steps disposed parallel to the work surface to be formed and joined at adjacent ends by transverse edge portions, each of said steps having a length more than four times its height, means for supporting a work piece and said cutter for relative bodily movement with the last work engaging steps coinciding with the surface to be produced, and power driven mechanism for relatively feeding the work and cutter during leach revolution of the latter a ldistance several times greater than the height of any step multiplied by the number of said edges but less than the longitudinal lengths of the individual steps multiplied by the number of edges.

8. The method of face milling a work piece which comprises providing on a rotatable support a series of generally radial cutter blades each having a series of individual cutting edges progressively stepped for successive work engagement and each edge having greater length than axial height, arranging said edges to form a plurality of spiral overlapping groups each comprising the outermost individual cutting edge on one blade` and the progressively inward individual edges on succeeding blades, positioning said work piece with the plane of the innermostindividual edges coinciding with the work surface to be formed, rotatingV said support, and simultaneously effecting relative feeding movement between said'support and said Work piece longitudinally of said plane to cause the edges of adjacent spiral groups to traverse overlapping curved zones on the work piece and the edges of the individual groups to remove from the respective zones successive layers of metal which are much longer in the direction 'of the feed than they are thick in a perpendicular direction.

9. The method of metal working which comprises subjecting the surface portion of a work piece to the actions of av plurality of generally radial rotating cutting edges each comprising longitudinally spaced portions stepped forsuccessive engagement with the work and having greater individual length in a direction normal to the rotational axis than in height, and relatively feeding the work piece and said edges at a continuous rate such as to cause spiral groups of said edge portions each comprising the successive inwardly spaced edge portions of successive blades to cut from overlapping arcuate zones of the work respective successions of metal layerseach having greater width in the direction of feed than in thickness whereby to leave a continuous smooth surface formed by the innermost of said edge portions.

` 10. The method of face milling a metallic work piece which -comprises rotating a cutter head having al plurality of approximately radial blades each provided with a plurality of individual cutting edges lying respectively in planes normal to the axis of the cutter and axially spaced decreasing distances apart toward the head, and causing relative movement between the work piece and said rotating head totraverse across a common zone of the work piece the outermost edge on one blade and the successive inwardly spaced edges of 'succeeding blades whereby to remove from such zone successive metal layers of decreasing individual thickness and of'individual width in the direction of feed more than four times the thickness.

11. The method of face milling a metallic workl piece which comprises rotating a cutter head having a plurality of approximately radial blades each provided with a plurality of individual cutting edges lying respectively in spaced planeswhich extend normal to the axis of the cutter, and causing relative movement between the work piece and said rotating head to traverse the successive inwardly spaced edges of successive blades across a common curved zone of the work piece at a rate such that the successive edges of each group remove 4successive metal layers of greater width in the direction of said movement than thickness due to the spacing of said planes.

12. The method of metal working which comprises subjecting thefsurface portion, of a work piece to the actions of a plurality of annularly spaced rotating cutting edges each divided into parallel steps for-successive engagement with the work having greater individual length than height, and relatively feeding the work piece and said edges at a continuous rate such as to cause the first steps of successive blades to cut from overlapping zones of the work metal layers of greater width in the direction of feed than in thickness, thel successive steps of succeeding blades coacting with each of said rst steps to remove successive layers of similar proportions from said zones whereby to leave a continuoussmooth surface.

13. For use in a cutter adapted to form a smooth surface on a work piece when rotated and relatively fed in a direction parallel to said surface', a cutter blade comprising a block of gen erally rectangular shape having a short transverse cutting edge portion and a long continuous longitudinal cutting edge merging therewith and divided into a plurality, more than four, of straight longitudinally spaced steps with additional transverse cutting edge portions connecting the adjacent ends of the adjacent steps, efch of said steps having a height not exceeding .020 of an inch and being of a length at least ten times greater than height, and the height of the steps decreasing in a plurality of stages along said longitudinal edge in a direction away from said short Y edge portion.

14. The method of face milling a metallic work piece which comprises revolving a series of generally` radial cutting edges arranged in a plurality of substantially radially extending steps and the successively acting inwardly spaced steps of each group disposed in axially separated planes spaced apart distances equal to a small fraction of the individual length of the steps, supporting a work piece with the plane of the innermost one of said steps coinciding with the iinal work surface to be produced.A and moving the work piece and the revolving edges bodily relative to each other and longitudinally of said planes -at a rate such as to advance the successive inwardly spaced steps ofV successive edges across a common zone ,of the work and cause removal therefrom of successive metal layers each having a width in the direction ofthe feed several times as great as the thickness in a perpendicular direction,

15. The method of removing metal to form a continuous surface on a work piece which comprises revolving a plurality of sets of cutting edges about a cmmonaxis with the edges of the respective sets arranged in overlapping spiral formations and the edges of each set adapted for the removal of thin metal'slices progressingV from the rough surface to the final work surface and disposed generally lparallel thereto, and relatively feeding the work and said series of cutting edges longitudinally of said final surface at a `rate such as to advance the spiral sets of edges successively across progressively advancing zones of the work -and cause eachedge of one of said sets toremove from one of said zones a metal Vslice of a width in the direction of the feed several times as great as the thickness in a perpendicular direction.

16. The method of removing metal to form a ment.

plane surface on a work piece which comprises revolving a series of cutting edges about a common 'axis perpendicular to said surface with the edges arranged to produce a substantially uniform cutting torque in all angular positions of the edges and to remove thin metal slices progressing from the rough surface to the' final work surface and disposed generally parallel thereto, and `relatively feeding the work and said series of cutting edges longitudinally of said final surface at a rate such as to advance the spiral sets Aof edges successively across progressively advancing overlapping zones of the work and cause the edges of each set to remove from one of said zones metal slices each having a width in the direction of the feed several times as great as the thickness in a perpendicular direction.

17. A machine for removing metal from a work piece to form a plane surface thereon comprising, in combination, a. cutter head having aseries of generally radial cutting edges projecting from one end thereof and each divided longitudinally into a plurality of steps each adapted to cut a thin slice of metal disposed in a plane approxi# mately parallel to the plane of the desired nal surface, the outermost step of each cutting edge and the successive inwardly spaced steps of successive edges being positioned progressively along the cutter axis and also in a spiral row which embraces as many edges as there are steps on each individual edge and overlaps a plurality of adjacent spiral rows, means for rotating said cutter, and means for causing relative feeding movement between said cutter and a piece of work in a direction parallel to the final surface to cause the overlapping spiral sets of steps to remove from progressive zones of the work successive slices of metal of substantially greater width in the direction of the feed than thickness in a perpendicular direction.

18. A machine for removing-metal from a work piece to form a continuous surface thereon comprising, in combination, a cutter head having a 'series of cutting edges arranged in a plurality of circumferentially ,overlaping spiral sets and each adapted to cut a thin slice of metal disposed vgenerally parallel to the desired nal surface, the

successively acting edges of each spiral set progressing toward said final surface, means forro-l tating said cutter, and means for causing relative feeding movement between said cutternand a piece of work in a direction parallel to the final vsurface to cause each overlapping spiral set of steps to remove from a common zone of the work successive slices of metal of substantially greater width in the direction of the feed than thickness 'in a perpendicular direction.

row overlapping the adjacent rows substantiallythroughout the major portion of its lengthl means for rotating said series of blades, and means for relatively feeding the workpiece andsaid4 seriesV v.

of rotating blades along'a pathof cutting engage- 20. A method of removing metal from a work piece, which comprises rotating about an axis a series of generally radial blades 'each having a plurality of stepped cutting edges lying in planes approximately normal to said axis, with the successive annular series of edges in corresponding steps, from the outermost step inward, lying in individual planes progressively spaced along said axis and disposed in common annular zonesV of progressively smaller radius, and with the inwardly successive edges in the successive blades of a group arranged in spiral rows overlapping each other circumierentially, and causing relative feed between said series of blades and the work piece in a direction normalto said axis and at such a rate as to cause the successive cutting edges of any individual spiral row to remove progressively thin layers of metal from a comon zone v of the work piece.

21. Ay cutter for forming a smooth surface on a work piece when the cutter is rotated and is relatively fed in a direction parallel to said surface, said cutter comprising a body adapted for rotation about a central axis. a plurality of blades projecting from said body and having cutting edges each divided longitudinally into five or more steps, of which all except the final step are of equal length, said steps being less than twenty thousandths of an inch in height and decreasing in height from the first to nal steps, the length of each step being more than ten times the spacing between any two adjacent steps, the end step of each blade and the successive longitudinally spaced steps of successive bladesbeing arranged in a spiral row which embraces as many blades circumferentially as there are steps on each individual blade, whereby each row overlaps the two adjacent'rcws and projects at its ends beyondl such rows by the distance between two adjacent blades.

22. A cutter for removing a layer of metal from a workpiece to form a smooth surface thereon by relative feeding movement between the cutter and the work piece parallel to said surface, said cutter comprising a rotary body, and a. plurality of angularly spaced blades thereon having elongated cutting edges divided longitudinally into a series of steps disposed generally parallel to the intended direction of feed of the cutter, the first work engaging step of each blade and the successive longitudinally spaced steps of successive blades being arranged in a spiral helical row which overlaps the two adjacent rows and embraces as many blades circumferentially as there are steps on each individual blade, the height of the individual steps being so small that the cutter may be relatively fed in a direction longitudinally of said edges at a. rate per blade approaching the length of each step without increasing the thickness of the metal slices removed by the respective steps.

23. A., cutter..for forming a smooth surface on a work piece when the cutter is rotated and is relatively fed in a direction parallel to said surface, said cutter comprising a body adapted for rotation about a central axis, a plurality of blades projecting from one end face of said body and having generally radial cutting edges each divided longitudinally into at least Afour steps lying in planes approximately perpendicular to said axis, the spacing between each twoadjacent planes being so small that the cutter and work piece may be relatively fed at a rate per blade approaching the length of the individual steps without increasing the thickness o f the chips removed.

24. A cutter for forming a smooth surface on a work piece when the cutter is rotated andis relatively fedv in a direction parallel to said surface, said cutter comprising a body adapted for rotation about av central axis, a plurality of blades projectingv from one end face of said body and having generally radial cutting edges'each divided longitudinally into four or more steps lying in planes approximately perpendicular to said axfs and having individual lengths more than ten times their individual heights, the outermost step of each blade and the successive inwardly spaced steps of successive blades being arranged in a spiral row which embraces as many blades circumferentially as there are steps on each individual blade, whereby eachspiral row overlaps the two adjacent rows and projects at its ends beyond such rows by the distance between two adjacent blades.

25. A cutter for forming a smooth surface on la work piece when the cutter is rotated and is relatively fed in a direction parallel to said surface, said cutter comprising a body adapted for rotation about a central axis, a series of blades projecting from said body and having cutting 26. A machine for removing a. layer of metal from a work piece, comprising, in combination, a cutter head carrying a series of blades each having a large number of stepped cutting edges, the

edges on the series of blades being arranged in a n plurality of overlapping spiral helical rows, means for rotating said cutter, and means for relatively feeding the work piece and said cutter along a path of cutting engagement.

Y CHARLES EDWARD mums. 

